Reciprocating Gas Compressor Valve

ABSTRACT

A reciprocating gas compressor valve having a plurality of clusters of kidney shaped holes positioned along a common circular or annular locus in the main body and a sealing element with a top portion, a bottom portion and a tubular section. The tubular section is integrally connected to the top portion and bottom portion. In an open position, a flow pathway is provided through the clusters of kidney shaped holes and the tubular section and the bottom profile abuts a stop surface of the valve. In a closed position, the top profile abuts the seat for sealing gas flow within the valve.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.15/770,715, entitled Reciprocating Gas Compressor Valve, filed on Apr.24, 2018, now U.S. Pat. No. 10,941,763, which is a U.S. national stageapplication under 35 USC § 371 of International PCT Application NumberPCT/US2016/058668, filed Oct. 25, 2016, which claims the benefit of U.S.Provisional Application No. 62/246,383, filed Oct. 26, 2015. Theforegoing applications are incorporated herein by reference.

BACKGROUND OF THE INVENTION

Reciprocating gas compressor valves require a significant amount ofstrength to withstand high differential pressures that occur at highspeeds in reciprocating gas compressors. In the reciprocating gascompressor valve, the sealing element engages a valve seat in order toclose gas flow passage ways. This type of valve is used in verydemanding and often corrosive applications. Therefore, there is a highdemand for a reciprocating gas compressor valve having a sealing elementthat will endure.

Existing sealing elements include a perforated plate, a ring or apoppet. The sealing element and a spring are contained in a valveassembly with the seat and a guard. The seat comprises a series ofholes, generating an area for fluid flow. The sealing element movesfreely in an axial direction. During operation, high pressure gas forcesare placed on the sealing element, thus opening the valve. At the end ofa cycle, the sealing element is pushed towards the seat often due tospring force, resulting in the seat surface being sealed and the valvein a closed position, and thereby obstructing the reverse flow andcreating a one direction flow path. The sealing element then movesreciprocally between the seat and a stop surface to an open positionwhere gas passes over the sealing element. The sealing element can movebetween suction and discharge events of the valve at a rate of 100 to1200 times per minute.

Further, often a cartridge is used in the reciprocating gas compressorvalve. The cartridge is press fitted into a hole and contains a sealingsurface. Over time, the cartridge sealing surface deteriorates thatcauses leakage and inefficient operation. If left untreated, this canresult in severe damage of the compressor and a costly overhaul of thewhole compressor system.

In addition, a reciprocating gas compressor valve often requires largeholes or slots in order to handle the proper amount of gas flow withinthe valve and as required by the compressor. The hole is drilled intothe seat in order to accommodate cartridge which is then press-fittedinto the hole. However, having a large area for the hole, the seat willlose structural integrity or seat strength. To compensate for this loss,the height of the seat must be increased to withstand the operatingpressures. This increased height, in turn, increases the open space inthe valve assembly resulting in increased clearance.

Further, it is beneficial to minimize pressure drop across the valve andincrease its efficiency. However, increasing lift of the sealing elementwithin the reciprocating gas compressor can require the overall area forlift and to accommodate an enlarged diameter for holes. However, largeseat holes can cause extrusion of the sealing element at highdifferential pressures and result in valve failure.

Therefore, a need exists to have a valve assembly with enhancedefficiency in operation while retaining maximum flow area possible andwithout compromising reliability. In addition, it is desired toeliminate an increased height of the seat so as to eliminate gasbecoming trapped in the clearance space.

SUMMARY OF THE INVENTION

A reciprocating gas compressor valve is provided having a seat with amain body and a plurality of clusters of holes positioned along a commoncircular or annular locus in the main body. Each cluster of holes hastwo kidney shaped holes. The reciprocating gas compressor valve furthercomprises a sealing element having a top portion, a bottom portion and atubular section. The top portion has a top profile. The tubular sectionis integrally connected to the top portion and bottom portion. Thebottom portion is raised and has a bottom profile. In an open position,a flow pathway is provided through the clusters of kidney shaped holesand the tubular section and the bottom profile abuts a stop surface ofthe valve. In a closed position, the top profile abuts the seat forsealing gas flow within the valve.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an overall perspective view of an embodiment of thereciprocating gas compressor valve;

FIG. 2 is an overall exploded perspective view thereof;

FIG. 3 is an overall top view thereof;

FIG. 4 is an overall side elevational view thereof;

FIG. 5 is a bottom view thereof;

FIG. 6 is a cross-sectional view of the reciprocating gas compressorvalve of FIG. 3;

FIG. 7 is an overall top view of the seat of the reciprocating gascompressor valve of FIG. 1;

FIG. 8 is a side elevational view of the seat thereof;

FIG. 9 is a bottom view of the seat thereof;

FIG. 10 is an overall top view of the guard of the reciprocating gascompressor valve of FIG. 1;

FIG. 11 is a side elevational view of the guard thereof;

FIG. 12 is a bottom view of the guard thereof;

FIG. 13 is a top perspective view of an embodiment of the sealingelement;

FIG. 14 is a side elevational view thereof;

FIG. 15 is a top view thereof;

FIG. 16 is a bottom view thereof;

FIG. 17 is a cross-sectional view thereof;

FIG. 18 is a top perspective view of an embodiment of the sealingelement;

FIG. 19 is a side elevational view thereof;

FIG. 20 is a top view thereof;

FIG. 21 is a bottom view thereof;

FIG. 22 is a cross-sectional view thereof;

FIG. 23 is a top perspective view of an embodiment of the sealingelement;

FIG. 24 is a side elevational view thereof;

FIG. 25 is a top view thereof;

FIG. 26 is a bottom view thereof;

FIG. 27 is a cross-sectional view thereof;

FIG. 28 is a top perspective view of an embodiment of the sealingelement;

FIG. 29 is a side elevational view thereof;

FIG. 30 is a top view thereof;

FIG. 31 is a bottom view thereof;

FIG. 32 is a cross-sectional view thereof;

FIG. 33 is a top perspective view of an embodiment of the sealingelement;

FIG. 34 is a side elevational view thereof;

FIG. 35 is a top view thereof;

FIG. 36 is a bottom view thereof;

FIG. 37 is a cross-sectional view thereof;

FIG. 38 is a top perspective view of an embodiment of the sealingelement;

FIG. 39 is a side elevational view thereof;

FIG. 40 is a top view thereof;

FIG. 41 is a bottom view thereof;

FIG. 42 is a cross-sectional view thereof;

FIG. 43 is a top perspective view of an embodiment of the sealingelement;

FIG. 44 is a side elevational view thereof;

FIG. 45 is a top view thereof;

FIG. 46 is a bottom view thereof;

FIG. 47 is a cross-sectional view thereof;

FIG. 48 is a top perspective view of an embodiment of the sealingelement;

FIG. 49 is a side elevational view thereof;

FIG. 50 is a top view thereof;

FIG. 51 is a bottom view thereof;

FIG. 52 is a cross-sectional view thereof;

FIG. 53 is an overall perspective view of an embodiment of thereciprocating gas compressor valve;

FIG. 54 is an overall exploded perspective view thereof;

FIG. 55 is an overall top view thereof;

FIG. 56 is an overall side elevational view thereof;

FIG. 57 is an overall bottom view thereof;

FIG. 58 is a cross-sectional view of the reciprocating gas compressorvalve of FIG. 18;

FIG. 59 is an top view of the seat of the reciprocating gas compressorvalve of FIG. 16;

FIG. 60 is a side elevational view of the seat thereof;

FIG. 61 is a bottom view of the seat thereof;

FIG. 62 is a perspective view of the cartridge of the reciprocating gascompressor valve of FIG. 53;

FIG. 63 is a bottom perspective view of the cartridge thereof;

FIG. 64 is a top view of the cartridge thereof;

FIG. 65 is a bottom view of the cartridge thereof;

FIG. 66 is a side view of the cartridge thereof;

FIG. 67 is a perspective view of the cartridge of the reciprocating gascompressor valve of FIG. 53 showing an embodiment of a sealing element;

FIG. 68 is a bottom perspective view thereof;

FIG. 69 is a top view thereof;

FIG. 70 is a bottom view thereof;

FIG. 71 is a side view thereof;

FIG. 72 is an overall top view of the guard of the reciprocating gascompressor valve of FIG. 53;

FIG. 73 is a side elevational view of the guard thereof;

FIG. 74 is a bottom view of the guard thereof;

FIG. 75 is an overall perspective view of an embodiment of thereciprocating gas compressor valve having a guard;

FIG. 75A is an overall perspective view of the reciprocating gascompressor valve without a guard;

FIG. 76 is an overall exploded perspective view of the reciprocating gascompressor valve of FIG. 75 thereof;

FIG. 76A is an overall exploded perspective view of the reciprocatinggas compressor valve of FIG. 75A thereof;

FIG. 77 is an overall top view of the valves of FIGS. 75 and 75A;

FIG. 78 is an overall bottom view of the reciprocating gas compressorvalve of FIG. 75;

FIG. 78A is an overall bottom view of the reciprocating gas compressorvalve of FIG. 75A;

FIG. 79 is an overall side view of the reciprocating gas compressorvalve of FIG. 75;

FIG. 79A is an overall side view of the reciprocating gas compressorvalve of FIG. 75A;

FIG. 80 is a cross-sectional view of the reciprocating gas compressorvalve of FIGS. 3 and 75;

FIG. 80A is a cross-sectional view of the reciprocating gas compressorvalve of FIG. 75A;

FIG. 81 is a top view of the seat of the reciprocating gas compressorvalve of FIG. 1;

FIG. 82 is a side view thereof;

FIG. 83 is a bottom view of thereof;

FIG. 84 is a top perspective view of a cartridge of the reciprocatinggas compressor valve of FIG. 75;

FIG. 85 is a bottom perspective view thereof;

FIG. 86 is a top view thereof;

FIG. 87 is a bottom view thereof;

FIG. 88 is a side elevational view thereof;

FIG. 89 is a top perspective view of the cup of the reciprocating gascompressor valve of FIG. 75;

FIG. 90 is a bottom perspective view thereof;

FIG. 91 is a top view thereof;

FIG. 92 is a bottom view thereof;

FIG. 93 is a side elevational view thereof;

FIG. 94 is a top perspective view of the cup assembly of thereciprocating gas compressor valve of FIG. 75;

FIG. 95 is a bottom perspective view thereof;

FIG. 96 is a top view thereof;

FIG. 97 is a bottom view thereof;

FIG. 98 is a side elevational view thereof;

FIG. 99 is a top view and bottom view of the plate of the reciprocatinggas compressor valve of FIG. 75;

FIG. 100 is a side view thereof;

FIG. 101 is a top view of the guard of the reciprocating gas compressorvalve of FIG. 1;

FIG. 102 is a side elevational view thereof;

FIG. 103 is the bottom view thereof;

FIG. 104 is an overall perspective view of an embodiment of thereciprocating gas compressor valve;

FIG. 105 is an overall exploded perspective view thereof;

FIG. 106 is an overall top view thereof;

FIG. 107 is an overall bottom view thereof;

FIG. 108 is an overall side view thereof;

FIG. 109 is a cross-sectional view of FIG. 3;

FIG. 110 is a top view of the seat of the reciprocating gas compressorvalve of FIG. 104;

FIG. 111 is a side elevational view thereof;

FIG. 112 is a bottom view of thereof;

FIG. 113 is a top view of the cartridge plate of the reciprocating gascompressor valve of FIG. 104;

FIG. 114 is a side elevational view thereof;

FIG. 115 is a bottom view of thereof;

FIG. 116 is an overall perspective view of the spacer ring of thereciprocating gas compressor valve of FIG. 104;

FIG. 117 is a top view and a bottom view thereof;

FIG. 118 is a side elevational view thereof;

FIG. 119 is a top view of the guard of the reciprocating gas compressorvalve of FIG. 104;

FIG. 120 is a side view thereof; and

FIG. 121 is a bottom view thereof.

FIG. 122 is a top perspective view of an embodiment of the sealingelement;

FIG. 123 is a side elevational view thereof;

FIG. 124 is a top view thereof;

FIG. 125 is a bottom view thereof;

FIG. 126 is a cross-sectional view thereof;

FIG. 127 shows data of effective flow area versus lift for areciprocating compressor valve shown in FIG. 1 having eight (8) sealingelements shown in FIGS. 122 to 126; and

FIG. 128 show data of effective flow area versus lift for areciprocating compressor valve shown in FIG. 1 having eight (8) sealingelements shown in FIGS. 122 to 126.

DETAILED DESCRIPTION

As shown in the figures, reciprocating gas compressor valve 100(sometimes referred to as the “gas compressor valve,” “compressor valve”or “valve) comprises a seat 10 (also referred to as a seating plate), aguard 12 (also referred to as a guard plate), a sealing element 20 and aspring 22. The seat 10 comprises a main body 94 and a plurality ofclusters of holes 16. The sealing element 20 comprises a tubular section24 connected to the top portion 19. Together, the top portion 19 and thetubular section 24 of the sealing element 20 provide a flow pathway 32for gas. Thus, in an open position, gas can flow through the pluralityof clusters of holes 16 through the tubular section 24 of the sealingelement 20.

The seat 10 comprises a main body 94 having the plurality of clusters ofholes 16. Each of the clusters of holes 16 extend longitudinally from anouter side 60 of the seat 10. The reciprocating gas compressor valve 100can optionally comprise a guard 12. The guard 12 has a plurality ofopenings 40 a, 40 b, 40 c, and a port 76, each port corresponding withone of the cluster of holes 16 in the seat 10. In an embodiment, theseat 10 and the guard 12 can be assembled together as a valve assembly44 (FIG. 2). Here, the sealing element 20 and the spring 22 arecontained in the valve assembly 44. The guard 12 can have a stop surface89 in a spaced relationship from seating surfaces 72 and 74 of the seat10 and associated with each cluster of holes 16 and shown in FIG. 10through FIG. 12. See also, U.S. Pat. No. 5,511,583, Col. 4 1. 22 through29, incorporated herein by reference. The guard 12 has flow passagesfrom an inner side thereof to an outer side which communicate with thespace between the stop surface 89 and the seat 10.

The sealing element 20 has the tubular section 24 integrally connectedto the top portion 19 of the sealing element 20 having an inner diameter54 and an outer diameter 56. See e.g., FIGS. 13 through 52. The topportion 19 of the sealing element 20 has a top profile 30.

FIGS. 13 to 17 show an embodiment of the sealing element 20 with the topprofile 30 having an angled V-shaped profile shape 52 having the innerdiameter 54 and the outer diameter 56 rounded. With the angled V-shapedprofile shape 52, gas flow is guided from the seat inlet holes 16 toguard outlet holes 40 a, 40 b, 40 c and 76. The contour 53 of theseating surfaces 72 and 74 corresponds to the profile shape 52 ensuringthat sufficient sealing is achieved in the closed position and when thetop profile 30 is in contact with the seating surfaces 72 and 74.

FIGS. 18 to 22 show an embodiment of the sealing element 20 with the topprofile 30 having a flat-shaped profile shape 57 and the inner and outerdiameters 54, 56 being rounded. In this embodiment, the contour 53 (notshown) of the seating surfaces 72 and 74 corresponds to the flat-shapedprofile shape 57 to ensure that sufficient sealing is achieved in theclosed position and when the top profile 30 is in contact with theseating surfaces 72 and 74.

FIGS. 23 to 27 show an embodiment of the sealing element 20 with the topprofile 30 having a combination of the angled V-shaped profile shape 52and the flat-shaped profile shape 57 having the inner diameter 54 andouter diameter 56. The angled V-shaped profile shape 52 is approximatelyat a mid-point 55 between the inner diameter 54 and the outer diameter56 and is designed to direct incoming gas flow from the holes 16 overthe portion of the top profile having the flat-shaped profile shape 57and to the guard outlet openings (40 a, 40 b and 40 c). The portion ofthe top profile 30 having the flat-shaped profile shape 52 seals thevalve when the top profile 30 is in contact with the seating surfaces 72and 74

FIGS. 28 to 32 show an embodiment of the sealing element 20 with the topprofile 30 having a concave-shaped profile shape 51 with two concaveshaped curves 59 a, 59 b which flatten at the inner diameter 54 and theouter diameter 56 of the sealing element 20. The concave shaped curves59 a, 59 b are designed to direct incoming gas flow from the holes 16 tothe guard outlet holes 40 a, 40 b, 40 c. The line of contact betweenconcave shaped curves 59 a, 59 b can be rounded as well as the innerdiameter 54 and the outer diameter 56. The seating surfaces 72, 74 sealthe valve 10 when the top profile 30 is in contact with seating surfaces72, 74.

FIGS. 33 to 37 show an embodiment of the sealing element 20 with the topprofile 30 having a U-shaped profile shape 61 sloping downwardsymmetrically from the mid-point 55 between the inner diameter 54 andthe outer diameter 56 of the sealing element 20. FIGS. 38 to 42 show anembodiment of the sealing element 20 with the top profile 30 having theflat-shaped profile shape 57 with chamfers 63 at the inner diameter 54and the outer diameter 56. The chamfers 63 serve several purposesincluding directing gas flow from holes 16 to the guard openings 40 a,40 b, 40 c when the valve is in an open position. FIGS. 43 to 47 show anembodiment of the sealing element 20 with the top profile 30 having acombination of the flat-shaped profile shape 57 and the concave-shapedprofile shape 51. FIGS. 48 to 52 show an embodiment of the sealingelement 20 with the top profile 30 having a combination of theflat-shaped profile shape 57 and U-shaped profile shape 61. Theflat-shaped profile shaped 57 is at the mid-point 55 and the U-shapedprofile shape 61 is positioned at the inner diameter 54 and the outerdiameter 56.

A bottom profile 26 of the sealing element 20 abuts the stop surface 89of the guard 12. Having a specially designed bottom profile 26 of thesealing element 20, static friction is reduced. Further, as shown in thefigures, the bottom profile 26 of the sealing element 20 is raised toreduce the area in contact with a guard 12, producing less friction inhigh oil applications and increasing reliability of the valve inoperation.

The sealing element 20 can be machined from off the shelf rings of hardplastic, and more specifically, of a polymeric material which is highimpact resistant, as well as chemical and heat resistant, or molded toreduce manufacturing costs. Each sealing element 20 can be of large andsmall size variations as shown in the drawings and to simplify toolingand production. To accommodation a range of valve sizes, the number ofclusters are increased or decreased in order to allow for differentvalve sizes. The number of clusters can vary according to the number ofholes 16 and openings 40 a, 40 b, 40 c and 40 d. The smaller sizedsealing element results in a higher number of clusters which in turnmake efficient use of available smaller surface area. The size of thesealing element 20 can be standardized not only for a given valve, butover the various sizes of reciprocating gas compressor valves 100, asshown in Table 1.

TABLE I Multiple Sealing Elements Used in Compressor Valve 100 ValveSize Sealing Element Size (in inches) Small  <5 Medium between 4 and 14Large >10

The tubular section 24 streamlines gas flow through center of thetubular section 24. The tubular section 24 directs gas flow in anoutward direction through the port 76. A minimal amount of gas flow isin contact with the spring 22 because the spring is shielded to reduceturbulence in gas flow and the amount of pressure drop. Hence, gasflowing through the sealing element 20 experiences a lower pressure dropand has a higher flow rate as a result of the reduced turbulence in thegas. Hence, gas flowing through the sealing element 20 has a higher flowrate as a result of the reduced turbulence in the gas. The turbulencecan be as much as 60 percent lower because of the elimination of gascontact with the spring 22 in the spring pocket region (not shown). Thespring 22 is protected from debris because gas flow is directed outwardthrough the tubular region. In the reciprocating gas compressor valve100, each cluster 66 or 68 of holes 16 comprises two kidney shaped holes16 that improve the structural integrity of the seat 10. Further, thegas compressor valve 100 can be made having a thinner seat 10 that alsoresults in lower manufacturing costs and reduced clearance volume.Therefore, the seat 10 can be constructed for maximum possible flowintake without compromising the strength of the seat 10.

In an embodiment, the guard 12 can have a plurality of guides 34. Seee.g., FIG. 10. The interior of each of the guides 34 provides a port 76generally aligned with one of the clusters of holes 16 and an annularaperture 18 (FIG. 5). The inner side 78 of rim 35 of guard 12 abuts theinner side 70 of the seat 10, but the guides 34 do not (FIG. 6). Exceptfor the guides 34 and sufficient interconnecting members 36 to connectcylinders 34 to the plate rim 35, guard 12 is completely open.

In an embodiment, each of the ports 76 has two sections or portions: afirst portion 80 sized to slideably receive the spring 22, and a secondportion 82 opening outwardly through the outer side 88 of guard 12. Thetop of guide 34 provides an annular stop surface 89 spaced from theinner side 70 of the seat 10. Each port 76 is sized to receive a spring22 where the spring 22 rests upon a shoulder formed within the port 76.The sealing element 20 can move reciprocally in the axial directionbetween a stop surface 89 of the guard 12 and the opposed seatingsurfaces 72 and 74 of the seat 10. Valve lift can be controlled byincreasing or decreasing the distance between the stop surface 89 andthe seating surfaces 72, 74. One side of the sealing element 20 abutsseating surfaces 72 and 74 when the valve is in the closed position.Sealing surfaces 90 and 92 generally correspond to the seating surfaces72 and 74. The seating surfaces 72 and 74 are sized and shaped to engagewith the sealing element 20 and to create a seal between the sealingelement 20 and seating surfaces 72 and 74. In an embodiment, the spring22 can be supported by the guard 12 to engage the sealing element 20 andto bias the sealing element 20 toward the seating surfaces 72 and 74 ofseat 10.

As shown in FIG. 2, in an embodiment, the seat 10 and the guard 12 canbe secured together in opposing relation by a plurality of screws 14.Furthermore, as shown in this embodiment, and others described herein,the reciprocating gas compressor valve 100 is oriented for use as anintake valve. However, it would be possible to use precisely the sameform of valve as an exhaust valve by simply reversing its orientation,vertically. The seat 10 can have a thickness reduced at the periphery ofits outer side 60 to form an annular, radially projecting flange 62.Similarly, the guard 12 can have a thickness reduced adjacent to theperiphery of its outer side to form an abutting radially projectingannular flange 64 of similar width as flange 62 and aligned therewith,See e.g., FIG. 6. Thus, the flanges 62 and 64, in the assembly, jointlyform a flange whereby the valve may be mounted between the cage (notshown) and the cylinder pocket (not shown) of a reciprocating gascompressor.

As described herein, and shown in FIGS. 1 to 12 and FIGS. 53 to 112 inthe reciprocating gas compressor valve 100, the seat 10 has a pluralityof clusters 68 of holes 16 extending longitudinally into the plate fromits outer side 60. More specifically, in one embodiment of the valve,each of the clusters comprises two holes 16 a and 16 b in the shape ofkidneys positioned along a common circular or annular locus. The holescan be circular in shape wherein each cluster 66, 68 will have more thantwo holes 16. Each hole 16 is not only arcuate, when viewed in plan,but, as viewed longitudinally in the figures, each hole has a widthtapering inwardly from the outer side 60 of the seat 10 toward its innerside 70. The hole 16 terminates short of inner side of the seat 70. Eachhole 16 of each cluster 68 intersect a common annular aperture 18 whichopens through the inner side of the seat 10 to define a seating surface90, more specifically, the seating surface 90 with an inner annularseating surface 72 and an outer annular seating surface 74, adjacent theinner and outer diameters, respectively, of annular aperture 18. Theseating surface 90 is preferably tapered toward the inner side 70 of theseat 10 but the seating surface 90 does not have to be tapered and canbe flat. They may, for example, define either spherical or conical loci.As shown in the figures, one of the plurality of clusters 66 of holes 16is central having the holes 16 b, 16 c, 16 d and 16 e spaced radiallyoutwardly and circumferentially from one another.

As shown in FIGS. 13 through 52, the sealing element 20 of thereciprocating gas compressor valve 100 provided herein is generallyplanar on one side and has the bottom profile 26 for abutment with astop surface 89. However, approximately midway between its inner andouter diameters, that side of the sealing element 20 is provided with anannular recess which receives one end coil of the spring 22. The sealingelement 20 can travel between the closed position engaging the seatingsurfaces 72 and 74, and an open position engaging stop surface 89. Thespring 22 will normally urge the sealing element 20 into its closedposition. Whenever the pressure in the adjacent end of the gascompressor cylinder and the ports 76 is lower than the pressure of thegas being taken in to such a degree so as to overcome the force of thesprings 22, the valves will open. When these pressure conditions arereversed, the valves will again be closed by the force of the springs22.

In addition, a bottom profile 26 of the sealing element 20 at the bottom28 of the sealing element 20 can be provided. The bottom profile 26 ofthe sealing element 20 abuts the stop surface 89 of the guard 12. When aguard 12 is not used, the bottom profile 26 is in contact with a cupassembly 44 shown in FIG. 80. The bottom profile 26 of the sealingelement 20 is raised at the bottom 28 to reduce the area in contact withthe guard 12, producing less friction in high oil applications andincreasing reliability of the valve in operation.

Other than force from the spring 22, the sealing element 20 generallydoes not require positive mechanical guidance to move or travel betweenthe open position and the closed position described above. Generally,the sealing element 20 aligns with the seating surfaces 72 and 74 forseveral reasons. First, as shown in FIGS. 2 and 6, there is asubstantial amount of guidance from spring 22 and counter bores 23 inthe guard 12. The spring 22 is guided by the inner diameter of theenclosing portion of the guides 34. Counter bore 23 retain the sealingelement 20 and each side of the counter bore 23 center the sealingelement 20 providing guided vertical movement of the sealing element 20.Second, once the sealing element 20 begins to move into alignment withits seating surfaces 72 and 74, the tapers of the seating surfaces 72and 74 and the sealing surfaces 72, 74 of the sealing element 20 canposition the sealing element 20 into proper alignment with its seatingsurfaces 72, 74. Third, when the guard 12 is included in the valveassembly 44, incoming gas can flow along both the inner and outerdiameters 54, 56 of the sealing element 20 and the guides 34 center thesealing element 20.

The sealing element 20 has certain sealing properties that include linecontact, and ring and surface contact. For example, line contact in thesealing region involves designing elements with tight tolerances andexcellent manufacturing capabilities. Any divergence from this resultsin valve leakage negatively affecting performance of that unit,resulting in higher operating costs. However, having adequate surfacecontact in the sealing region reduces leakage due to excellent sealingproperties. This has the capability of absorbing some manufacturinganomalies and does not require tight tolerances. Turbulence can bereduced also. The tube in the sealing element helps streamline gas flowthrough center of the ring. Since, springs are covers and the fluid isnot in contact with springs, turbulence decreases resulting in increasedefficiency.

The sealing element 20 moves freely in an axial direction in the seat10. During operation of the reciprocating gas compressor valve 100, inan open position, high pressure gas forces move the sealing element 20.At the end of a cycle, in a closed position, the sealing element 20 ispushed in a reverse direction due to force of the spring 22 therebyobstructing the reverse flow and creating a one direction flow path andresulting in gases sealed within the cylinder (not shown).

More specifically, as shown in the figures and described above, thesealing element 20 moves by reciprocating between the stop surface 89and the respective seating surfaces 72 and 74. As shown in FIGS. 13 to52, one side of a top portion 19 of the sealing element 20 faces and,when the valve is closed, abuts seating surfaces 72, 74, and has sealingsurfaces 90, 92 adjacent to an inner and an outer diameter of thesealing element, respectively, and inclined toward each other, togenerally correspond to the taper of seating surfaces 72, 74. Forexample, if surfaces 72 and 74 define spherical loci, surfaces 90 and 92define mating spherical loci; if surfaces 72 and 74 define conical loci,surfaces 90 and 92 can define mating conical loci; etc. However, otherarrangements are possible. For example, surfaces 72 and 74 could defineconical loci, with surfaces 90 and 92 defining spherical loci tangent tothe respective conical loci.

Optionally, as shown in FIG. 53 through FIG. 74, the reciprocating gascompressor valve 100 can comprise a cartridge 50. The cartridge 50 canbe press fitted into the seat 10, as shown in FIG. 54. Over time,sealing surfaces 90 and 92 of the sealing element 20 can deteriorate andcause leakage of gas and an overall inefficient operation. If leftuntreated, severe damage and a costly overhaul can result to the gascompressor valve 100 and possibly the gas compressor. However, thecartridge 50 can be replaced in the field using an Arbor press providedthe leakage is discovered prior to any extensive damage to thereciprocating gas compressor valve 100 and/or compressor. In thisembodiment, the main body 94 can have a plurality of recesses 96 in aninner side 70 of the main body 94, each recess generally aligned with acluster of holes 16. U.S. Pat. No. 5,511,583, Col. 3 1. 50 to Col. 4, 1.21 incorporated herein by reference. Therefore, the cartridge 50 canthen be positioned within the recess 96 to define an annular aperture 18having the seating surfaces 72 and 74.

The reciprocating gas compressor valve 100 can be used for gas intakeand gas exhaust of the reciprocating gas compressor (not shown). As itrelates to the reciprocating gas compressor valve 100, operativeportions of the reciprocating gas compressor include at least one piston(not shown) and a cylinder (not shown). The reciprocating gas compressorvalve 100 is located in the cylinder of the reciprocating garcompressor. Each cylinder has two ends: a head end and a crank end. Thereciprocating gas compressor valve 100 can be used on both the ends oreither end provided the valve 100 is single acting. The spring anddifferential pressure across the valve 100 causes the sealing element 20to move back and forth within the valve 100 and thereby provide one waygas flow through the cylinder.

In addition, the gas compressor valve 100 provided herein has a reducedclearance pattern between the guard 12 and the seat 10 with respect tothe prior compressor valves. Clearance pattern provides for example thatin certain reciprocating gas compressor valves, large holes are drilledto make room for the cartridges 50. The number of these holes isdirectly proportional to the valve diameter. These holes create deadvolumes in the valve and these volumes are not used in the compressioncycle. The fluid gravitates to these dead volumes and this constitutes aloss of flow or throughput. The summation of all these dead volumes iscalled valve clearance. Since this valve clearance does not contributein the compression cycle, they should be eliminated or reduced. Having areduced clearance pattern, the reciprocating gas compressor valve 100has a higher rate of flow (throughput) and an improved efficiency.

The greater the number of sealing elements 20 provided in the gascompressor valve 100, the more efficient it is in a cylinder pocket area(not shown) and more gas flow capacity. Reciprocating gas compressorvalves with relatively larger diameters require a greater number ofholes available for gas flow. More sealing elements can be positionedwithin the valve and this in turn increases the flow (throughput)through a valve pocket. The number of sealing elements will furtherincrease the clearance volume in the valve due to higher number ofholes. This clearance volume is in addition to the compressor clearancevolume. See, Compressor Handbook Hanlon; section 20.7.1, incorporatedherein by reference. Dead space in the valve is minimized. The seat 10,the guard 12 and valve lift remain in balance. Higher number ofnon-metallic individual sealing elements also increases valve life. Theuseful life of a reciprocating gas compressor valve can be affected byvarious abnormalities in the system. One of those is liquids condensedor present in the system. Valves having individual sealing elementstolerate liquids better than valves having only one sealing element.See, Compressor Handbook Hanlon, Section 20.6: Valve Life, incorporatedherein by reference.

As shown in FIGS. 53 through 74, in an embodiment, the cartridge 50 andthe sealing element 20 are fixed, matched and interchangeable. Theplurality of clusters of holes 16 each have holes with reduced diameterscompared to other prior art reciprocating gas compressor valves and theholes 16 can be produced in two standardized sizes, i.e., a large and asmall size. Moreover, the cartridge 50 is thinner than in the previousreciprocating gas compressor valve. For example, the cartridge 50 canhave a width of ⅛ as opposed to ⅞ inch.

As further shown in FIGS. 75 through 103, in an embodiment of the gascompressor valve 100, a non-metallic or metallic cup assembly 48 and aplate 38 are provided. In the gas compressor valve 100, the sealingelement 20 and a spring 22 fit into the cup assembly 48, as shown inFIG. 80 and FIGS. 94 through 98, which removes the need for guard 12.The reciprocating gas compressor valve can be assembled with a guard orwithout a guard.

The cup assembly 48 is intended to ease manufacturing because hightolerances are not necessary. In an embodiment of the gas compressorvalve 100, the seat 10 supports the cup assembly 48. The width of theseat 10 is, therefore, reduced. In this embodiment of the reciprocatinggas compressor valve 100, the seat 10 provides large holes 46 that fitthe cartridges 50. As shown in FIG. 76, in the valve assembly 44, eachplate hole 39 corresponds a seat hole 46. The number of plate holes 39and seat holes 46 depend on the size of the reciprocating gas compressorvalve 100. The cup assembly 48 provides straightforward tolerancemeasurement which serve to keep production costs down. The gascompressor valve 100 having the cup assembly 48 can include a spring 22.

As shown in FIGS. 104 through 121, in an embodiment of the reciprocatinggas compressor valve 100, the valve 100 includes a cartridge 50 and aspacer ring 42. The cartridge plate 58 is used in lieu of the cartridge50 to lower the thickness of the seat 10 and provide reduced clearance.The cartridge plate 58 has arcuate holes which align with the clustersof holes to result in seamless gas flow intake. The spacer ring 42provides the required area for sealing element movement.

Reciprocating compressors are used extensively in the oil and gasindustry. Multiple cylinders can be mounted on the reciprocating gascompressor frame for increased throughput. To permit a one directionflow, the gas compressor valve is used in the cylinder at the suctionand discharge location. The gas compressor valve can be used at eitherlocation by reversing its direction. Typical industrial applications forthe gas compressor valves include gas gathering, refining, storage, andpipeline transport. Each application requires a different set ofoperating conditions.

Reciprocating gas compressors are typically used for gases with lowmolecular weight to heavy gases such as methane that require differentpressure ratios and may include some impurities. The gas compressorvalve is used in very demanding and often corrosive applications.Therefore, there is a high demand for gas compressor valves withcomponents that endure. Typically, most reciprocating gas compressorvalves must be replaced or refurbished at fixed time interval toeliminate catastrophic failure.

Example I Increased Flow Area

Certain prior art valves utilize press fitted cartridges into the seatand one end of the cartridge serves as the sealing surface for thesealing element. The number of cartridges contained in the valve 100 isdirectly proportional to the diameter of the seat 10. In these prior artvalves, the seat has a series of holes that are drilled into the seat tomaximize the amount of flow area and serve as the inlet to thereciprocating gas compressor valve. Equivalent flow area is used tocompare valves of similar dimensions.

To calculate this area, the reciprocating gas compressor valve 100 isconsidered as a fabrication of three orifices in series. A dischargecoefficient can be calculated by testing this valve in a flow tunnel.The discharge coefficient in this example is considered as one. Thethree orifice areas are described as seat area, lift area and guardarea. The seat area is defined as the summation of all open spaces in aseat in the axial direction. This is the area of all the tapered holesin the seat. The lift area equals total of inner and outercircumferential length of the sealing element multiplied by the valvelift. The guard area is defined as summation of all the holes present inthe axial direction. Hence, equivalent flow area can be shownmathematically as:

$\phi = {Q*\sqrt{\frac{\rho}{2*\Delta P}}}$

To increase the flow area in this cartridge (seat area), the area of theholes must be increased. However this reduces the size of the “threebridges” that hold the cartridge together. Reduced size of these bridgesresults in increased stresses weakening the cartridge load carryingcapacity. Because the cartridge is press fitted, a reduction in size maydistort the cartridge and cause failure due to stress induced by pressfit.

As shown in FIGS. 127 and 128, the reciprocating gas compressor valveshown in FIGS. 1 to 6 was assembled with the sealing element shown inFIGS. 18 through 22 for an analysis. The reciprocating gas compressorvalve had eight sealing elements and was in completely pen condition.Further the same valve was made with a larger diameter to accommodateeleven (11) sealing elements. FIGS. 127 and 128 show the improvements ineffective flow area in comparison with prior art reciprocatingcompressor valve and for the different sizes and at different lifts. Atlower lifts, there is significant improvement in flow area withcomparison to at higher lifts. The result is a cost saving in devicesand methods where gases have lower molecular weight and lower lift. Ahigher effective flow area resulted in low power consumption leading tolower energy costs. Flow tunnel testing and computational fluid dynamicswere used to calculate the effective flow area.

Example II Percent Reduction in Clearance

Clearance volume is the residual space in the compressor cylinderoccurring at the end of the stroke. Clearance comprises spaces in thevalve recess and the space between the piston and the cylinder end. Highclearance results in more residual gas trapped at end of each stroke,resulting in lower volumetric efficiency. Lower clearance is desiredbecause it increases the volumetric efficiency of the compressor andassociated processes.

In addition to compromising the seat strength, when large holes arerequired in a reciprocating gas compressor valve, the height of the seathas to be increased. As large diameter holes assist to increase flowarea, the height of the seat has to be increased to compensate for areduction in structural strength. Increasing the height expands the openspace in the valve and results in enlarged dead volumes. Gas can thenmigrate into these dead volumes during compression cycle resulting inreduced throughput. The dead volume is often referred to as a “valvefixed clearance” and should be minimized as it directly affectsperformance of the compressor.

Clearance in compressor is a combination of valve clearance and cylinderfixed clearance. It can be a major issue for compressors with smallervalves. Since small compressors have smaller cylinders resulting insmaller fixed clearance, any additional clearance in valves produces apenalty in performance. Large compressors have large cylinders andhigher fixed clearance. Therefore, valve clearance is a very smallpercentage of total fixed clearance in the cylinder. But a largeclearance in a small compressor has a significant effect on compressorperformance. Hence, valve clearance is critical for smaller compressorswith small diameter valves. Thus valve with a smaller diameter wasconsidered for this calculation.

TABLE II Percentage Clearance Reduction Clearance (in{circumflex over( )}3) Total Clearance Suction Discharge Reduction Existing Valve 12.9211.91 New Valve 12.14 11.35 % Reduction −6.07% −4.66% −10.73%

Table II shows the clearance value comparison for the valves. The valvefixed clearance at the suction and discharge ends of prior art valvesare 12.92 cubic inches and 11.91 cubic inches respectively. Thisclearance is calculated using by volumetric formulae for cylinder andCAD software calculated volume numbers as shown in the followingequation:

Clearance=Valve Envelope Volume−Model Volume

In the new reciprocating gas compressor valves, large cartridge holesare not present in the seat. Hence, the seat strength is not compromisedand the extra seat height is not required. This eliminates the openspaces for a similar sized valve and lowers the dead volume. However,the valve fixed clearance reduction will be different for differentdiameters of valves. The clearances at the suction and discharge endsare 12.14 cubic inches and 11.35 cubic inches respectively, representinga reduction of approximately 6% and 4.5% at suction and discharge ends.Hence the combined reduction in clearance is ˜10.5% for the valvesprovided herein.

Example III Reciprocating Gas Compressor Test

The reciprocating gas compressor valves both existing and thereciprocating gas compressor valve shown in FIGS. 1 to 6 having asealing with the design shown in FIGS. 18 to 22 were manufactured forcompressor testing in a single cylinder, double acting, reciprocatingcompressor. The compressor is instrumented with pressure taps atcritical locations. In our testing, temperature readings were taken byinline gas measurement device. A 500 hp electric motor was used to drivethis compressor. A VFD drive was used to control the test speed.Nitrogen was used as the test fluid. This compressor had a complete loopwith a cooling tower. Test was performed at 700 rpm with a pressureratio of 2.0. Suction and discharge pressures were maintained at 100 psiand 215 psi respectively.

Data (flow, multiple pressures and temperatures) was collected by theelectronic data analyzer using the various pressure taps and analyzed tocheck for any abnormalities. An inline flowmeter was installed on thesuction side to monitor the fluid flow. Furthermore, a kW meter wasmonitoring the power used by the motor to verify IHP calculations takenby the electronic analyzer.

This testing performed under controlled environment. Flow was measuredwith a flow meter and Indicated Horsepower/MMSCFD was calculated usingthe data.

For a prior art valve, flow and IHP/MMSCHD was observed as 1180 SCFM and48.54 IHP/MMSCFD respectively. For reciprocating gas compressor valvesprovided herein, the numbers improved to 1350 SCFM and 45.48 IHP/MMSCFDrespectively, representing an improvement of ˜14% in Flow and IHP/MMSCFDreduced by ˜6%. The customer can calculate dollar savings using theequation below. Data will be different, however, for different fluids,applications, pressure ratios and diameter of valves.

$\left( {{Customer}\mspace{14mu}{Savings}} \right)\mspace{11mu}{\frac{\$}{MMSCFD} = {\frac{IHP}{MMSCFD}*\frac{\$}{{HP} - {hr}}}}$

The certain symbols provided above and used herein are defined herein asfollows: Q: Flow through the valve; ϕ: Equivalent Flow area; a: Bendingstresses; ρ: fluid density ΔP: Pressure differential across the valve;M: Moment about the neutral axis; I; Second Moment about the neutralaxis; y: distance from neutral axis; w: width of the bridge; h: heightof the bridge; IHP: Indicated horsepower; MMSCFD: Million MetricStandard Cubic Feet per Day; and HP-hr: Horsepower hour.

We claim:
 1. A reciprocating gas compressor valve comprising: a seathaving a main body and a plurality of clusters of holes positioned alonga common circular or annular locus in the main body, wherein each of theclusters has two kidney shaped holes; and a sealing element having a topportion, a bottom portion and a tubular section, the top portioncomprising a top profile, the tubular section is integrally connected tothe top portion and bottom portion, the bottom portion is raised and hasa bottom profile, wherein in an open position, a flow pathway isprovided through the clusters of kidney shaped holes and the tubularsection and the bottom profile abuts a stop surface of the valve, and ina closed position, the top profile abuts the seat for sealing gas flowwithin the valve.
 2. The reciprocating gas compressor valve of claim 1further comprising a guard, wherein the bottom portion of the sealingelement is contiguous with the guard in the open position.
 3. Thereciprocating gas compressor valve of claim 2, wherein the guardcomprises a plurality of openings, wherein each opening is adjacent toone of the cluster of holes.
 4. The reciprocating gas compressor valveof claim 1, further comprising a seat wherein the seat has a lowclearance volume.
 5. The reciprocating gas compressor valve of claim 3,wherein the guard controls the travel of the sealing element.
 6. Thereciprocating gas compressor valve of claim 1, wherein the sealingelement comprises a non-metallic material.
 7. The reciprocating gascompressor valve of claim 1, wherein a coil spring is positioned betweenthe sealing element and the guard to time movement of the sealingelement.
 8. The reciprocating gas compressor valve of claim 1, furthercomprising a cartridge or a cartage plate operably engaged with thesealing element.
 9. The reciprocating gas compressor valve of claim 1further comprising a plurality of sealing elements.
 10. Thereciprocating gas compressor valve of claim 9, wherein the reciprocatinggas compressor valve further comprises a plurality of guides forpositioning a plurality of sealing elements.